Method and apparatus for manufacturing solid electrolytic capacitor

ABSTRACT

(a) supplying a capacitor element manufacturing apparatus, in which the capacitor element manufacturing apparatus includes a polymerization tank, a polymerization solution contained in the polymerization tank, and a negative electrode put in the polymerization solution in the polymerization tank, (b) supplying a core material having a plurality of capacitor elements, in which each capacitor element of the plurality of capacitor elements has an anode lead-out portion and a cathode lead-out portion, (c) forming a formation film on the surface of the core material, (d) installing a conductive substance on the formation film, (e) adhering each anode lead-out portion of the plurality of capacitor elements having the conductive substance to a conductive tape, (f) immersing the core material having the anode lead-out portion adhered to the adhesive tape in the polymerization solution, and (g) forming a polymerization film on the cathode lead-out portion of the capacitor element by applying a voltage to the conductive tape are included. By applying a voltage to this conductive tape, the polymerization reaction starts from the surface of the conductive tape, and this polymerization spreads to the cathode lead-out portion of each capacitor of the plurality of capacitors. Polymerization films are formed simultaneously on the cathode lead-out portions of the capacitor elements. As a result, the productivity is notably enhanced.

FIELD OF THE INVENTION

[0001] The present invention relates to a method and apparatus formanufacturing a solid electrolytic capacitor having a solid electrolyte.

BACKGROUND OF THE INVENTION

[0002] Recently, as the power source circuit of an electronic applianceis becoming higher in frequency, an electrolytic capacitor having anexcellent high frequency characteristic is demanded. To meet thisdemand, in order to realize a low impedance in a high frequency region,a solid electrolytic capacitor using a conductive high polymer of highconductivity obtained by electrolytic polymerization as solidelectrolyte.

[0003] In a conventional solid electrolytic capacitor, when forming apolymerization film of high polymer by electrolytic polymerizationsimultaneously on a cathode lead-out portion of a plurality of capacitorelements, as shown in FIG. 22, an electrolytic polymerization must beperformed in a polymerization solution 1, by setting a current feedingelectrode 3 to contact with each anode lead-out portion 2, with thiselectrode 3 used as the positive electrode, and applying a voltagebetween the positive electrode 3 and a negative electrode 4.

[0004] In the conventional manufacturing method of solid electrolyticcapacitor, however, a polymerization electrode 3 must be prepared foreach capacitor element, and it requires a complicated process of makingcontact between each polymerization electrode 3 and anode lead-outportion 2. It was hence difficult to mass-produce efficiently.

[0005] The invention presents a manufacturing method of solidelectrolytic capacitors suited to mass production.

SUMMARY OF THE INVENTION

[0006] A manufacturing method of solid electrolytic capacitor of theinvention comprises:

[0007] (a) a step of supplying a capacitor element manufacturingapparatus,

[0008] in which the capacitor element manufacturing apparatus includes apolymerization tank, a polymerization solution contained in thepolymerization tank, and a negative electrode put in the polymerizationsolution in the polymerization tank,

[0009] (b) a step of supplying a core material having a plurality ofcapacitor elements,

[0010] in which each capacitor element of the plurality of capacitorelements has an anode lead-out portion and a cathode lead-out portion,

[0011] (c) a step of forming a formation film on the surface of the corematerial,

[0012] (d) a step of installing a conductive substance on the formationfilm,

[0013] (e) a step of adhering each anode lead-out portion of theplurality of capacitor elements having the conductive substance to aconductive tape,

[0014] (f) a step of immersing the core material having the anodelead-out portion adhered to the adhesive tape in the polymerizationsolution, and

[0015] (g) a step of forming a polymerization film on the cathodelead-out portion of the capacitor element by applying a voltage to theconductive tape.

[0016] A manufacturing apparatus of solid electrolytic capacitor of theinvention comprises:

[0017] a supplying device for supplying a core material having aplurality of capacitor elements,

[0018] in which each capacitor element of the plurality of capacitorelements has an anode lead-out portion and a cathode lead-out portion,

[0019] a formation film forming device for forming a formation film onthe surface of the core material,

[0020] a conductive substance forming device for installing a conductivesubstance on the formation film,

[0021] an adhering device for adhering the plurality of capacitorelements having the conductive substance to a conductive tape,

[0022] a polymerization device for forming a conductive polymerizationfilm on the surface of the cathode lead-out portion of core materialadhered to the conductive tape, and

[0023] a peeling device for peeling the conductive tape from the corematerial forming the polymerization film.

[0024] Preferably, the core material has a band shape.

[0025] Preferably, the polymerization tank has a long shape.

[0026] By applying a voltage to this conductive tape, the polymerizationreaction starts from the surface of the conductive tape, and thispolymerization spreads to the cathode lead-out portion of each capacitorof the plurality of capacitors. Thus, polymerization films are formedsimultaneously on the cathode lead-out portions of the capacitorelements. As a result, the productivity is notably enhanced.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027]FIG. 1 is a block diagram of a manufacturing method of solidelectrolytic capacitor in an embodiment of the invention.

[0028]FIG. 2 is a plan of one manufacturing state of capacitor elementused in the manufacturing method of solid electrolytic capacitor in theembodiment of the invention.

[0029]FIG. 3 is a plan of other manufacturing state of capacitor elementused in the manufacturing method of solid electrolytic capacitor in theembodiment of the invention.

[0030]FIG. 4 is a plan of a different manufacturing state of capacitorelement used in the manufacturing method of solid electrolytic capacitorin the embodiment of the invention.

[0031]FIG. 5 is a sectional view of one manufacturing state of capacitorelement used in the manufacturing method of solid electrolytic capacitorin the embodiment of the invention.

[0032]FIG. 6 is a sectional view of a polymerization tank for forming apolymerization film in the manufacturing method of solid electrolyticcapacitor in the embodiment of the invention.

[0033]FIG. 7 is a perspective view of the polymerization tank forforming a polymerization film in the manufacturing method of solidelectrolytic capacitor in the embodiment of the invention.

[0034]FIG. 8 is a sectional view of the polymerization tank for forminga polymerization film in the manufacturing method of solid electrolyticcapacitor in the embodiment of the invention.

[0035]FIG. 9 is an electric block diagram of the polymerization tank forforming a polymerization film in the manufacturing method of solidelectrolytic capacitor in the embodiment of the invention.

[0036]FIG. 10 is an electric block diagram of other polymerization tankfor forming a polymerization film in the manufacturing method of solidelectrolytic capacitor in the embodiment of the invention.

[0037]FIG. 11 is a sectional view of a first driven roller used in thepolymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0038]FIG. 12 an essential magnified sectional view of the first drivenroller in FIG. 11.

[0039]FIG. 13 is a sectional view of a first tension roller used in thepolymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0040]FIG. 14 is a perspective view of a second tension roller used inthe polymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0041]FIG. 15 is a perspective view of a first current feed roller usedin the polymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0042]FIG. 16 is a sectional view of the first current feed roller usedin the polymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0043]FIG. 17 is a perspective view of a voltage application terminalunit used in the polymerization tank for forming a polymerization filmin the manufacturing method of solid electrolytic capacitor in theembodiment of the invention.

[0044]FIG. 18 a perspective view of a peeling roller used in thepolymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0045]FIG. 19 is a plan of a first peeling pawl used in thepolymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0046]FIG. 20 is a sectional view of the first peeling pawl used in thepolymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0047]FIG. 21 is a perspective view of a second current feed roller usedin the polymerization tank for forming a polymerization film in themanufacturing method of solid electrolytic capacitor in the embodimentof the invention.

[0048]FIG. 22 is a sectional view of a polymerization tank for forming apolymerization film in a conventional manufacturing method of solidelectrolytic capacitor.

REFERENCE NUMERALS

[0049]5 Core material

[0050]6 Slit

[0051]7 Capacitor element

[0052]8 Insulating tape

[0053]9 Anode lead-out portion

[0054]10 Cathode lead-out portion

[0055]16 Conductive tape

[0056]17 polymerization tank

[0057]18 Polymerization solution

[0058]19 Negative electrode

[0059]23 First driven roller

[0060]24 First tension roller

[0061]25 Through-shaft

[0062]26 Ball bearing

[0063]27 Drive shaft

[0064]28 Lid

[0065]29 Spacer

[0066]30 Weir

[0067]31 First current feed roller

[0068]33 Dust collecting squeegee

[0069]34 Second driven roller

[0070]35 Third driven roller

[0071]36 Separator

[0072]37 Reel

[0073]38 a, 38 b Second tension roller

[0074]39 Position defining plate

[0075]42 Voltage application terminal

[0076]45 Peeling roller

[0077]46 Cracking roller

[0078]47 First peeling pawl

[0079]48 Second peeling pawl

[0080]49 Roller

[0081]50 Suction means

[0082]51 Second current feed roller

[0083]53 a, 53 b Tension roller

[0084]70 Polymerization device

[0085]71 Supplying device

[0086]72 Formation film forming device

[0087]75 Conductive substance forming device

[0088]76 Adhering device

[0089]79 Peeling device

DETAILED DESCRIPTION OF THE INVENTION

[0090] A manufacturing method of solid electrolytic capacitor of theinvention comprises:

[0091] (a) a step of supplying a polymerization tank, a polymerizationsolution contained in the polymerization tank, and a negative electrodeput in the polymerization solution in the polymerization tank,

[0092] (b) a step of supplying a core material having a plurality ofcapacitor elements,

[0093] each capacitor element of the plurality of capacitor elementshaving an anode lead-out portion and a cathode lead-out portion,

[0094] (c) a step of forming a formation film on the surface of the corematerial,

[0095] (d) a step of installing a conductive substance on the formationfilm,

[0096] (e) a step of adhering each anode lead-out portion to aconductive tape,

[0097] (f) a step of immersing the core material adhered to the adhesivetape in the polymerization solution, and

[0098] (g) a step of forming a polymerization film on the cathodelead-out portion of the capacitor element by applying a voltage to theconductive tape.

[0099] In this constitution, by applying a voltage to the conductivetape, the polymerization reaction starts from the surface of theconductive tape, and this polymerization spreads to each cathodelead-out portion, and polymerization films are formed on the cathodelead-out portions of the capacitor elements. By this constitution, theproductivity is notably enhanced.

[0100] A manufacturing apparatus of solid electrolytic capacitor of theinvention comprises:

[0101] a supplying device for supplying a core material having aplurality of capacitor elements,

[0102] in which each capacitor element of the plurality of capacitorelements has an anode lead-out portion and a cathode lead-out portion,

[0103] a formation film forming device for forming a formation film onthe surface of the core material,

[0104] a conductive substance forming device for installing a conductivesubstance on the formation film,

[0105] an adhering device for adhering the plurality of capacitorelements having the conductive substance to a conductive tape,

[0106] a polymerization device for forming a conductive polymerizationfilm on the surface of the cathode lead-out portion of core materialadhered to the conductive tape, and

[0107] a peeling device for peeling the conductive tape from the corematerial forming the polymerization film.

[0108] In this constitution, solid electrolytic capacitors havingexcellent capacitor characteristics are obtained. Further, thepolymerization film is formed easily, and the productivity is notablyenhanced.

[0109] Preferably, the core material has a band shape, the step ofsupplying the core material includes a step of projecting and formingthe plurality of capacitor elements integrally in a direction orthogonalto the longitudinal direction, in the longitudinal direction of the corematerial, and each anode lead-out portion is positioned at the projectedroot side of each capacitor element. In this constitution, when formingthe polymerization film, the plurality of capacitor elements can behandled as one body. Hence, the productivity is further enhanced.

[0110] Preferably, the step of supplying the core material includes astep of projecting and forming the capacitor elements integrally in adirection orthogonal to the longitudinal direction of the core material,at both sides of the longitudinal direction of the band-shaped corematerial. In this constitution, when forming the polymerization film,the plurality of capacitor elements can be handled as one body. Hence,the productivity is further enhanced.

[0111] Preferably, the core material has a band shape, the step ofsupplying the core material includes a step of forming a plurality ofslits in the direction orthogonal to the longitudinal direction, atevery specific interval in the longitudinal direction of the corematerial, and each capacitor element is formed between slits. In thisconstitution, by the step of forming only slits at specific intervals inthe longitudinal direction of the band shape, a plurality of capacitorelements can be formed easily.

[0112] Preferably, the core material has a band shape, the step ofsupplying the core material includes a step of forming integrally theplurality of capacitor elements projected in the direction orthogonal tothe longitudinal direction, in the longitudinal direction of theband-shaped core material, the anode lead-out portion is positioned atthe root side of the plurality of projected capacitor elements, and theconductive tape is adhered to the surface of the anode lead-out portion.In this constitution, by adhering the conductive tape in thelongitudinal direction of the band-shaped core material, the distancebetween the cathode lead-out portion and conductive tape of eachcapacitor element is stable, so that a nearly homogeneous polymerizationfilm is formed in the cathode lead-out portion of each capacitorelement.

[0113] The manufacturing method of solid electrolytic capacitor furtherincludes a step of adhering a long insulating tape in the central regionin the longitudinal direction of the band-shaped core material, and the-conductive tape is adhered to the insulating tape. In thisconstitution, since this insulating tape surface has a smoother flatnessthan the core material on which the formation film is formed, it iseasier to adhere the conductive film. At a later step, this conductivetape can be easily peeled from the core material. As a result, theproductivity is improved. Moreover, since the anode lead-out portion andcathode lead-out portion underneath the conductive tape of eachcapacitor element are separated by the insulating tape, thepolymerization film formed on the negative electrode hardly invades intothe anode lead-out portion side.

[0114] The polymerization tank has a long shape. By forming thepolymerization tank in a long shape, the volume of polymerizationsolution for immersing the conductive tape in the state of adhering ofthe core material can be decreased.

[0115] The long-shaped polymerization tank has a plurality oflong-shaped polymerization tanks installed in parallel, and the step ofimmersing the core material in the polymerization solution includes astep of immersing the band-shaped core material having the anodelead-out portion adhered to the conductive tape in each polymerizationsolution in each long-shaped polymerization tank of the plurality oflong-shaped polymerization tanks. In this constitution, the productivityis notably enhanced.

[0116] The band-shaped core material to which the conductive tape isadhered moves so as to get into the polymerization solution from one endside of the long-shaped polymerization tank, and go out of thepolymerization solution from other end side. In this constitution, inthe polymerization tank, the polymerization film can be formedsequentially and continuously in the cathode lead-out portion of eachcapacitor element from one side to other side. Further, after formationof polymerization film, the core material forming the polymerizationfilm can be drawn out from the polymerization tank and move to the nextstep. As a result, the productivity is improved.

[0117] The polymerization solution flows into the polymerization tankfrom one end side of the long-shaped polymerization tank, and flows outof the polymerization tank from the other end side of the polymerizationtank. In this constitution, drop of concentration of polymerizationsolution in the polymerization tank is suppressed, and polymerizationfilms can be formed stably.

[0118] The core material to which the conductive tape is adhered getsinto the polymerization solution from one end side of the long-shapedpolymerization tank, and moves to go out of the polymerization solutionfrom other end side, and the polymerization solution flows into thepolymerization tank from one end side of the long-shaped polymerizationtank, and flows out of the polymerization tank from the other end sideof the polymerization tank, and the flow speed of the polymerizationsolution and the moving speed of the core material are nearly the same.By nearly equalizing the speed of the polymerization solution and corematerial moving from one side to other side of the polymerization tank,the relative state of each capacitor element of the core material andthe polymerization contacting therewith is almost constant, and in thisstate of a stagnant state where both remain still, the polymerizationfilm is formed. As a result, the polymerization film may be easilyformed in the cathode forming portion of each capacitor element.

[0119] The capacitor element manufacturing apparatus includes a firstdriven roller installed at one side in the polymerization tank, and afirst tension roller installed at other side in the polymerization tank,and at least the lower part of the first driven roller is immersed inthe polymerization solution, and at least the lower part of the firsttension roller is immersed in the polymerization solution and theband-shaped core material to which the conductive tape is adhered abutsagainst the lower part of the first driven roller and the lower part ofthe first tension roller, and is moved from one side to other side ofthe polymerization tank. In this constitution, by the first drivenroller at one side of the polymerization tank, the band-shaped corematerial can be immersed in the polymerization solution. By the firsttension roller at other side, the core material can be moved in thepolymerization tank while a proper tension is applied thereto. As aresult, contact of the core material with the bottom of thepolymerization tank at the time of moving is prevented, and anappropriate polymerization film is formed on each capacitor element.

[0120] From above at one side of the. polymerization tank toward thelower part of the first driven roller, the core material to which theconductive tape is adhered is moved in the polymerization solution in aninclined state of 30° or less. In this constitution, without peeling ofthe conductive tape, the core material smoothly moves in thepolymerization tank. As a result, the polymerization film is formedstably on each one of the plurality of capacitor elements provided inthe longitudinal direction of the band-shaped core material.

[0121] The polymerization solution flows into the polymerization tankfrom the upper direction than the first driven roller at one side of thepolymerization tank, and the polymerization tank at one side has aninclined bottom downward to the direction of installation of the firstdriven roller. In this constitution, the polymerization solution flowinginto the polymerization tank is a laminar flow, thereby preventingformation of waves on the polymerization solution in the polymerizationtank. As a result, the polymerization film can be formed stably on eachcapacitor element.

[0122] From the lower part of the first tension roller at other side ofthe polymerization tank toward the upper side of the polymerizationtank, the core material to which the conductive tape is adhered is movedout of the polymerization solution in an inclined state of 30° or less.In this constitution, peeling of the conductive tape from the corematerial is prevented. As a result, core material can be moved to thedownstream side stably together with the conductive tape.

[0123] The polymerization solution flows out of the polymerization tankfrom other end side of the polymerization tank, and the polymerizationtank at other end side has an inclined bottom upward to the other endside from the tension roller. In this constitution, the polymerizationsolution flowing out of the polymerization tank is a laminar flow,thereby preventing formation of waves on the polymerization solution inthe polymerization tank. As a result, the polymerization film can beformed stably on each capacitor element.

[0124] The capacitor element manufacturing apparatus includes each firstdriven roller installed at one side of each polymerization tank of theplurality of polymerization tanks, and one through-shaft penetrates thecentral shaft of each first driven roller. In this constitution, thesupport structure of the plurality of first driven rollers issimplified. In addition, the position of each first driven roller ineach polymerization tank is uniform. As a result, the immersing positionof the core material in the polymerization solution in eachpolymerization tank is uniform, and formation of polymerization film onthe capacitor element in each core material is stable.

[0125] The capacitor element manufacturing apparatus includes athrough-shaft formed in each first driven roller, and a ball bearinginstalled between the first driven roller and through-shaft, and thisball bearing is placed above the liquid level of the polymerizationsolution. Since the bearing is provided between the first driven rollerand the through-shaft, rotation of the first driven roller is smooth.Moreover, since this bearing is provided above the polymerizationsolution level, occurrence of defective rotation of the bearing due tosticking of polymerization solution is prevented. As a result, the firstdriven roller operates together with the band-shaped core material byadhering the conductive tape, so that disturbance of moving of the corematerial can be prevented.

[0126] The first driven roller has an outer circumference curved so thatthe center line portion may project in the outer circumferentialdirection, and the core material is moved while contacting with thecenter line portion. At one side of the polymerization tank, the firstdriven roller contacting with the band-shaped core material to which theconductive tape is adhered has a curved surface so that the center lineportion of the outer circumference projects in the outer circumferentialdirection, so that the core material is prevented from being deviationfrom the position of the center line portion of the first driven roller.Accordingly, by this first driven roller, the core material can bestably guided into one side in the polymerization tank.

[0127] The capacitor element manufacturing apparatus includes each firsttension roller installed at other side of each polymerization tank ofthe plurality of polymerization tanks, and one through-shaft penetratesthe center shaft of each first tension roller, and each tension rolleris driven by driving of the through-shaft. In this constitution, bydriving a plurality of first tension rollers disposed in parallel by onedrive shaft, the drive mechanism is simplified. Further, in each one ofthe polymerization tanks disposed in parallel, tension applied to theband-shaped core material is made almost uniform by the first tensionroller. As a result, the moving state of the band-shaped core materialin each polymerization tank is stable, and the polymerization film isformed stably.

[0128] The first tension roller has a flat outer circumference, and thecore material moves while contacting with the flat outer circumferenceof the first tension roller. By forming the outer circumference of thefirst tension roller in a flat shape, the outer circumference and theband-shaped core material to which the conductive tape is adheredcontact with each other in flat state so as to slide on each other. As aresult, tension application by the first tension roller is stable.

[0129] The polymerization tank has temperature control means installedunderneath the bottom of the polymerization tank, and the temperaturecontrol means controls the temperature of the polymerization solution.In this constitution, the polymerization reaction may be stabilized.

[0130] The specified temperature is controlled by the water controlledat the specified temperature. The polymerization tank has a constitutionof passing water controlled in temperature at the specified temperatureunderneath the bottom of the polymerization tank. Since the watercontrolled in temperature at the specified temperature has a larger heatcapacity as compared with gas, it is easier to stabilize the temperatureof the polymerization solution in the polymerization tank at thespecified temperature. As a result, the polymerization reaction isstabilized.

[0131] The polymerization tank has a spacer projecting into thepolymerization solution so as to separate from the upper surface of thepolymerization solution. If the volume of the polymerization solution isdecreased, the liquid level can be heightened by projecting the spacer.Therefore, the distance between the negative electrode and the corematerial can be extended. As a result, bubbles formed in the negativeelectrode hardly stick to the band-shaped core material portion. Hence,the polymerization film is formed stably in the cathode lead-out portionof the capacitor element of the band-shaped core material.

[0132] The polymerization tank has a lid installed in the opening of theupper surface, and a spacer installed at the lower side of the lid, andat least a part of the spacer is projecting into the polymerizationsolution. By disposing the lid on the upper opening of thepolymerization tank, and disposing the spacer at the lower side of thislid and projecting into the polymerization tank, the evaporation spaceof the upper surface of the polymerization solution and the surfaceexposed area of the polymerization solution are decreased. As a result,the evaporation of the polymerization solution decreases, and theeconomy is improved.

[0133] The step of immersing the core material to which the conductivetape is adhered in the polymerization solution includes a step of movingthe core material to which the conductive tape is adhered from one sideto other side of the polymerization tank through the lower side of thespacer. By moving the core material to which the conductive tape isadhered in the lower pat of the polymerization tank underneath thespacer, the oligomer formed at the time of forming the polymerizationfilm settles in the lower cored material portion. As a result, theforming efficiency of polymerization film is enhanced.

[0134] The spacer has a lower part of a slope inclined upward. Since thelower part of the spacer is an upward slope, bubbles formed in thenegative electrode can be moved upward. Therefore, the polymerizationfilm forming efficiency is enhanced in the capacitor element of theband-shaped core material moving underneath.

[0135] The negative electrode is disposed above the lower end of thespacer, and the step of applying voltage to the conductive tape includesa step of applying a voltage between the conductive tape and negativeelectrode. In this constitution, bubbles formed in the negativeelectrode hardly stay at the lower end of the spacer. As a result, thepolymerization film forming efficiency is enhanced in the capacitorelement of the band-shaped core material moving underneath.

[0136] The spacer is made of vinyl chloride. By forming the spacer ofvinyl chloride, degeneration of spacer and resulting degeneration ofpolymerization solution can be prevented. As a result, thepolymerization film is formed stably on the capacitor element of theband-shaped core material.

[0137] The negative electrode has a lower part in a shape inclinedupward. By guiding the bubbles formed in the negative electrode upward,it prevents drop of polymerization film forming efficiency due to moveof bubbles downward to the capacitor element of the band-shaped corematerial.

[0138] The polymerization tank has an upper space and a lower space, thelower space has a smaller sectional area than the upper space, thespacer and the negative electrode are disposed on the upper space, andthe core material passes through the lower space. By defining thesectional area of the core material moving portion in the lower part ofthe polymerization tank smaller than the sectional area of the spacernegative electrode storage part located above, disturbance of thepolymerization solution occurring in the upper spacer and the negativeelectrode storage part is prevented from affecting the core materialmoving part underneath. As a result, in the core material moving part,the polymerization film is formed stably on the capacitor element.

[0139] The conductive tape is adhered only to the upper side of the corematerial. Since the conductive tape is adhered to the upper side of thecore material in at the upper side of the negative electrode, thepolymerization film can be formed easily from the upper surface of thisconductive tape. Consequently, the polymerization film is formed so asto grow from the conductive tape and the cathode lead-out portionsurface of the capacitor element to the back side. Since conductive tapeis not disposed at the lower side of the core material, the productivityis higher by the corresponding portion.

[0140] The polymerization tank has an immersion region in the corematerial is immersed in the polymerization solution, and a weirinstalled on the liquid level between the immersing region and the firstdriven roller. In this constitution, bubbles formed in the negativeelectrode are prevented from sticking to the core material by floatingup to the liquid level of the polymerization solution. As a result,interference of polymerization in subsequent process is prevented. Thatis, by setting up the weir, move of bubbles floating to the liquid levelinto the direction of core material is blocked, and sticking to the corematerial and the resulting formation of defective polymerization filmcan be prevented.

[0141] The negative electrode has a plurality of negative electrodesdisposed in the longitudinal direction. In this constitution, thepotential difference between the parts of the conductive tape in thelongitudinal direction of the conductive tape adhered to the band-shapedcore material and the negative electrodes can be maintained within aspecified range. As a result, the polymerization film is substantiallyformed uniformly on the capacitor elements at each position of theband-shaped core material.

[0142] Each negative electrode of the plurality of negative electrodesis disposed at a specified interval, and the voltage applied to eachnegative electrode is individually different. By spacing the negativeelectrodes at a specified interval, bubbles formed in each negativeelectrode are prevented from staying in the adjacent negativeelectrodes. Hence, blocking of polymerization reaction in the bubblestaying area can be prevented. As a result, the polymerization film ofeach capacitor element can be formed stably.

[0143] The negative electrode is made of at least one of stainless steeland nickel. By forming the negative electrode of stainless steel ornickel, deterioration of negative electrode is prevented in spite ofpolymerization reaction. As a result, the polymerization film can beformed stably for a long period on the capacitor element at eachposition of the band-shaped core material.

[0144] The capacitor element manufacturing apparatus includes firstvoltage applying means installed at one side of the polymerization tankand second voltage applying means installed at other side, and each oneof the first voltage applying means and second voltage applying meansapplies a voltage to the conductive tape. By applying voltages to oneside and other side of the polymerization tank of the conductive tape,drastic potential fluctuation in the longitudinal direction of theconductive tape can be suppressed. As a result, the polymerizationreaction on the plurality of capacitor elements provided in thelongitudinal direction of the band-shaped core material is stabilized.

[0145] The capacitor element manufacturing apparatus includes a firstcurrent feed roller installed at one side of the polymerization tank,and the first current feed roller has an action of adhering theconductive tape to the core material, an action of pressing theconductive tape to the core material, and an action of applying avoltage to the conductive tape. By composing first voltage applyingmeans of the first current feed roller for pressing the conductive tapeto the core material, the constitution is simplified. Further, the firstcurrent feed roller presses the conductive tape to the core material, sothat it is pressed to the conductive tape. As a result, the voltageapplication to the conductive tape is stabilized, and the polymerizationfilm is stably formed on the capacitor element.

[0146] The capacitor element manufacturing apparatus includes a dustcollecting squeegee abutting against the outer circumference of thefirst current feed roller, and the deposits adhering to the outercircumference of the first current feed roller are removed by the dustcollecting squeegee. As the dust collecting squeegee abuts against theouter circumference of the first current feed roller, dust and foreigndeposits can be removed from the outer circumference of the firstcurrent feed roller. As a result, the voltage can be applied stably fromthe first current feed roller to the conductive tape, and thepolymerization film is formed stably on the capacitor element.

[0147] The capacitor element manufacturing apparatus includes a seconddriven roller installed at the upstream side of the first current feedroller, and the second driven roller has an outer circumferenceprojecting in the outer circumferential direction in the center lineportion, and the core material is supplied in the direction of the firstcurrent feed roller through the second driven roller. In thisconstitution, deviation of band-shaped core material is corrected by thesecond driven roller. Hence, the band-shaped core material moves withoutshifting in the direction of the first current feed roller. As a result,the conductive tape is adhered by the first current feed roller and thevoltage is applied stably.

[0148] The capacitor element manufacturing apparatus has a reelinstalled at the upstream side of the first current feed roller, thereel coils the conductive tape in a laminated state through a separator,and the separator is peeled from the conductive tape between the reeland the first current feed roller. Since the conductive tape is coiledon the reel in the laminated state with the separator, the conductivetape being let off from the reel is not curled even after the separatoris peeled. As a result, it is stable when supplying into the firstcurrent feed roller at the downstream side, and adhering to theband-shaped core material.

[0149] The capacitor element manufacturing apparatus has a secondtension roller installed between the reel and the first current feedroller, and the second tension roller grips a laminated body of theconductive tape and separator, and the separator is peeled from theconductive tape at the downstream side of the second tension roller.That is, a second tension roller is provided between the reel and thefirst current feed roller, and this second tension roller grips thelaminated body of the conductive tape and separator, and the tension isapplied outside of one side of the polymerization tank. In thisconstitution, sine the conductive tape and the separator forms alaminated body, the strength of the laminated body is increased. As aresult, a sufficient tension can be applied.

[0150] The capacitor element manufacturing apparatus includes a positiondefining plate disposed at both sides of the second tension roller, andthe position defining plate defines the position of the conductive tape.By disposing the position defining plate at both sides of the secondtension roller, deviation of the laminated body of the conductive tapeand separator at the second tension roller is prevented. Hence, arequired tension is stably added by the second tension roller.

[0151] The conductive tape is made of at least one of stainless steeland nickel. In this constitution, when performing polymerizationreaction by applying a voltage to this conductive tape, this conductivetape is prevented from eluting into the polymerization solution. As aresult, by using the conductive tape, polymerization reaction is donestably.

[0152] The step of applying a voltage includes a step of applying avoltage from the voltage application terminal to the core material bysetting the voltage application terminal in contact with the anodelead-out portion of the core material at the upstream side of the firstcurrent feed roller, and the applied voltage is a voltage between theenergization voltage by the first current feed roller and theenergization voltage by the negative electrode, and is same or higherthan the voltage in the portion of the conductive tape immersed in thepolymerization solution. In this constitution, the load voltage of thecapacitor terminal formed in the hand-shaped core material can besuppressed lower than the withstand voltage. As a result, breakage ofthe capacitor element can be prevented.

[0153] The formation film of the core material has an aluminum oxidefilm, and the voltage application terminal is made of stainless steel.The voltage application terminal can easily break down the aluminumoxide film. Accordingly, stable energization is possible. Further, sincethe voltage application terminal is made of stainless steel, the weatherresistance is enhanced. Further, if the rigid aluminum oxide film isrubbed by the terminal made of stainless steel, the stainless steelsurface is also scarred, and the surface is exposed. As a result,voltage is applied stably from the voltage application terminal to thecore material.

[0154] The capacitor element manufacturing apparatus includes a peelingroller installed outside of the polymerization solution in thepolymerization tank at the downstream side of the first tension roller,and this peeling roller peels off the conductive tape in the orthogonaldirection from the core material. In this constitution, without causingfluctuations, the conductive tape can be smoothly peeled from the corematerial. As a result, the conductive tape and core material can besmoothly moved to the downstream side.

[0155] The capacitor element manufacturing apparatus includes a crackingroller installed in the running path of the conductive tape at thedownstream side of the peeling roller, and this cracking roller has asmaller diameter than the peeling roller, and the cracking roller bendsthe running path of the conductive tape in the orthogonal direction. Inthis constitution, it is easy to form cracks in the polymerization filmon the conductive tape. Accordingly, it is easy in the process ofremoving the polymerization film from the conductive tape in thesubsequent steps.

[0156] The running path of the conductive tape between the peelingroller and the cracking roller has a dry space of the polymerizationfilm formed on the surface of the conductive tape. In this constitution,it is easy to form cracks in the polymerization film on the conductivetape. Hence, the removing job is easier in the subsequent steps.

[0157] The capacitor element manufacturing apparatus includes a firstpeeling pawl installed at the downstream side of the cracking roller,and the first peeling pawl contacts with the surface of the conductivetape bent by the cracking roller. In this constitution, the crackedpolymerization film is easily removed by the first peeling pawl.

[0158] The capacitor element manufacturing apparatus includes a secondpeeling pawl installed at the downstream side of the first peeling pawl,and the second peeling pawl contacts with the upper surface of theconductive tape. As the second peeling pawl contacts with the uppersurface of the conductive tape at the downstream of the first peelingpawl, the slight polymerization film not removed by the first peelingpawl can be easily removed by this second peeling pawl. Hence, in thesubsequent process, the voltage is applied stably from the upper surfaceof the conductive tape.

[0159] At least one of the first peeling pawl and second peeling pawlhas a leading end branched into a plurality. In this constitution, theremoving effect of the polymerization film at the leading end isenhanced.

[0160] The capacitor element manufacturing apparatus includes a rollerdisposed at the lower side of the conductive tape of at least one of thefirst peeling pawl and second peeling pawl. In this constitution, thefirst peeling pawl or second peeling pawl may be strongly pressed to theupper side of the conductive tape. Hence, the peeling effect of thepolymerization film may be enhanced.

[0161] The capacitor element manufacturing apparatus includes suctionmeans installed on the first peeling pawl. Since a large amount ofpolymerization film is removed in the first peeling pawl area, bysucking the removed polymerization film by the suction means, it iseffective to prevent the removed polymerization film from sticking againto the upstream or downstream side. As a result, occurrence of variousproblems can be prevented.

[0162] The capacitor element manufacturing apparatus includes a secondcurrent feed roller installed at the downstream side of the firstpeeling pawl. As the second current feed roller is installed as secondvoltage applying means on the upper surface of the conductive tape fromwhich the polymerization film is removed, it enhances the polymerizationfilm forming efficiency by applying a voltage from one side and otherside of the polymerization tank of the conductive tape.

[0163] The capacitor element manufacturing apparatus includes a secondcurrent feed roller as second voltage applying means installed at thedownstream side of the second peeling pawl. At the downstream side ofthe second peeling pawl, by installing the second current feed roller assecond voltage applying means on the upper surface of the conductivetape from which the polymerization film is cleanly removed, it enhancesthe polymerization film forming efficiency by applying a voltage fromone side and other side of the polymerization tank of the conductivetape.

[0164] The capacitor element manufacturing apparatus includes a tensionroller installed on the running path of the conductive tape at thedownstream side of the peeling roller. The tension roller pulls theconductive tape. By pulling the conductive tape by this tension roller,the band-shaped core material can be removed from one side to other sideof the polymerization tank. By applying this tension force to theconductive tape only by the tension roller, breakage of core material bypulling the band-shaped core material can be prevented.

[0165] The capacitor element manufacturing apparatus includes a tensionroller installed at the downstream side of the second current feedroller. In this constitution, a tension is applied also to theconductive tape when the second current feed roller is passing.Accordingly, it prevents formation of gap between the second currentfeed roller and conductive tape. As a result, the current is fed stablyfrom the second current feed roller and the conductive tape.

[0166] The capacitor element manufacturing apparatus includes a take-upreel installed at the downstream side of the tension roller, and thetake-up reel takes up the conductive tape. In this constitution, theconductive tape is taken up smoothly in the subsequent process. As aresult, it is effective to prevent occurrence of malfunction due toentangling of the conductive tape or the like.

[0167] The conductive substance has a manganese dioxide layer. In thisconstitution, formation of conductive substance is extremely easy.Further, a conductive film having an excellent conductive property canbe formed easily.

[0168] The step of forming the conductive substance includes a step ofapplying an aqueous solution of manganese nitrate on the formation film,and a step of forming a manganese dioxide layer by pyrolysis of theapplied aqueous solution of manganese nitrate. In this constitution, themanganese dioxide layer as a conductive layer can be formed easily.

[0169] The polymerization solution contains at least one monomerselected from the group consisting of pyrrole, thiophene, furan andtheir derivatives. The step of forming the polymerization film includesa step of for polymerizing at least one monomer electrolytically. Inthis constitution, an adequate polymerization film can be formed on thecapacitor element by polymerization reaction.

[0170] The polymerization solution is a mixed polymerization solution ofa first polymerization solution and a second polymerization solutionflowing out from other side of the polymerization tank. That is, thepolymerization solution supplied from one side of the polymerizationtank into this polymerization tank is mixed with the polymerizationsolution flowing out of the polymerization tank from other side of thepolymerization tank. In the polymerization solution flowing out of thetank from the other side of the polymerization tank, oligomer is formedby polymerization reaction. This polymerization containing oligomerflows into the tank from one side of the polymerization tank, and mixedinto the polymerization solution, so that the polymerization film isefficiently formed on each capacitor element in the polymerization tank.

[0171] Referring now to the drawings, a manufacturing method of solidelectrolytic capacitor in exemplary embodiments of the invention and itsmanufacturing method are described below.

[0172] Exemplary Embodiment 1

[0173]FIG. 1 is a conceptual diagram of a manufacturing apparatus ofsolid electrolytic capacitor in an embodiment of the invention. FIG. 2shows the state of forming a plurality of capacitor elements 7 at bothsides by cutting and forming slits 6 at specified intervals at bothsides of a band-shaped core material 5.

[0174] First, the core material 5 having a plurality of capacitorelements was supplied by a supplying device 71. As the core material 5,an aluminum foil (thickness: 100 μm) was used. The face and backsurfaces of the aluminum foil were roughened electrochemically. Ananodic formation film is formed on the face and back surfaces of thealuminum foil. Forming treatment was executed by applying a voltage of35 V. By adhering an insulating film 8 on the face and back surface ofthe aluminum foil having a formation film, it was separated into ananode lead-out portion 9 and a cathode lead-out portion 10. The size ofthe cathode lead-out portion 10 is 3 mm×4 mm.

[0175] Consequently, a formation film was formed by a formation filmforming device 72. That is, on the surface of the aluminum foil 5 havingslits 6 shown in FIG. 2, an anodic oxidation film was formed as aformation film by performing a formation treatment in a tank 11 (formingtreatment step 12 in FIG. 1).

[0176] In succession, a conductive substance layer was formed by aconductive substance forming device 75. That is, an aqueous solution ofmanganese nitrate in a polymerization tank 13 was applied on the cathodelead-out portion 10. Later, pyrolysis was performed in a furnace 14 for5 minutes at 300° C. In this process, a manganese dioxide layer wasformed on the cathode lead-out portion 10 as a conductive substancelayer (conductive substance forming step 15 in FIG. 1).

[0177] Then, as shown in FIG. 3, FIG. 4, and FIG. 5, the conductive tapewas adhered by an adhering device 76. That is, the conductive tape 16was adhered on an insulating tape 8 at both sides of the core material 5forming the manganese dioxide layer. The conductive tape 16 has a roleas a polymerization electrode for forming an electrolytic polymerizationlayer. The conductive tape 16 has a role as a positive electrode whenpolymerizing.

[0178] Next, a polymerization film was formed by a polymerization device70. That is, the core material 5 to which the conductive tape 16 isadhered is sequentially immersed in the polymerization solution 18 inthe polymerization tank 17, and is moved in the polymerization tank 17.The polymerization solution 18 is an aqueous solution containing 0.2mol/liter of pyrrole and 0.1 mol/liter of alkyl naphthalene sulfonate.As four independent cathodes 19, four stainless steel plates aredisposed beneath the liquid level in the polymerization tank 17. Avoltage is applied between the conductive tape 16 as a common positiveelectrode and four independent negative electrodes 19. By application ofthe voltage, polymerization started from the conductive tape 16, and apolymerization film of conductive high polymer was formed on the entirecathode lead-out portion 10 of the face and back surfaces in about 30minutes from entering and leaving the polymerization tank 17(polymerization film forming step 20 in FIG. 1).

[0179] Finally, the conductive tape 16 was peeled off by a peelingdevice 79. That is, after being taken out from the polymerizationsolution 18, the conductive tape 16 was peeled from the aluminum foilforming the conductive high polymer film.

[0180] In this way, a series of process from forming treatment tillpolymerization was carried out continuously as shown in FIG. 1. At thistime, the series of process was done with particular care given so thatthe conveying rollers might not contact with the cathode lead-outportion 10.

[0181] Moreover, after formation of the polymerization film ofconductive high polymer, a carbon paint layer and silver paint layerwere formed on the surface of this conductive high polymer film.Further, cutting individually so as to have the anode lead-out portion 9and cathode lead-out portion 10 as indicated by broken line in FIG. 2,one capacitor element was fabricated. Taking out the cathode lead fromthe cathode lead-out portion 10, and taking out the anode lead from theanode lead-out portion 9, the capacitor element was covered with anexternal epoxy resin. Thus, a solid electrolytic capacitor wascompleted.

[0182] In thus fabricated solid electrolytic capacitor, the initialcharacteristics were measured. Table 1 shows the results of measurement,that is, electrostatic capacity of solid electrolytic capacitor, tangentof loss angle, leak current (10 V applied, 2 minutes), and withstandvoltage (product breakdown voltage by raising voltage at a rate of 0.2V/1 sec).

[0183] Exemplary Embodiment 2

[0184] Similar to exemplary embodiment 1, a solid electrolytic capacitorwas fabricated in the following manner.

[0185] The cathode lead-out portion 10 measures 2 mm×2 mm. At the timeof electrolytic polymerization, the conductive tape 16 which is thepolymerization electrode was used as the positive electrode, and asingle stainless steel was used as the cathode 19. A voltage was appliedbetween the positive electrode and the cathode. At this time, apolymerization film of conductive high polymer was formed on the entirecathode lead-out portion 10 in about 10 minutes. The other manufacturingmethod is same as in exemplary embodiment 1. Thus, a solid electrolyticcapacitor was fabricated. The initial characteristics of the obtainedsolid electrolytic capacitor are shown in Table 1.

COMPARATIVE EXAMPLE 1

[0186] A conductor layer was placed on an aluminum foil having an oxidelayer, being roughened and slotted in the surface. As the conductorlayer, a chemical oxidation polymerization conductive high polymer filmof pyrrole was placed. Ammonium persulfate was used as the oxidizingagent in the chemical oxidation polymerization. Thus, a plurality ofcapacitor elements were formed.

[0187] Later, as shown in FIG. 22, each anode lead-out portion and eachcathode lead-out portion of individual elements were brought intocontact with the electrode 3, and electrolytic polymerization wasperformed on the chemical oxidation polymerization conductive highpolymer film. In this way, the conductive high polymer film was formedon the conductor layer. In this manner, a solid electrolytic capacitorof comparative example was prepared. The initial characteristics of thesolid electrolytic capacitor of the comparative example are shown inTable 1. TABLE 1 Electrostatic Tangent of Leak Withstand capacity lossangle current voltage (μF) (%) (μA) (V) Exemplary 1 3.42 1.2 0.02 23.1Exemplary 1.08 1.1 0.01 22.6 embodiment 2 Comparative 3.54 1.6 2.4 16.0example

[0188] As clear from the table, the solid electrolytic capacitors of theembodiments have a small leak current and a high withstand voltage.Further, by using the conductive tape 16 as the polymerization startingelectrode, electrolytic polymerization is done efficiently, and theconductive high polymer film can be formed efficiently on a plurality ofnegative electrodes. Moreover, since the plurality of capacitor elements7 are formed on the band-shaped core material, the electrolyticpolymerization is performed continuously. As a result, as compared withthe comparative example, the productivity is notably enhanced.

[0189] Instead of the aluminum foil used as the core material 5,meanwhile, tantalum, titanium or other metal may be used. The shape andsize of the core material are not limited to the embodiments, andarbitrary shape and size may be used.

[0190]FIG. 6, FIG. 7, and FIG. 8 show the detail of the constitution ofthe polymerization film forming step 20 in FIG. 1.

[0191] The polymerization film forming device at the polymerization filmforming step 20 includes a polymerization tank 17, a polymerizationsolution 18 contained in this polymerization tank 17, and a negativeelectrode 19 installed in the polymerization solution 18 in thepolymerization tank 17. This polymerization film forming step 20includes a step forming a formation film on the surface of the corematerial 5, and a step of forming a polymerization film on the surfaceof the cathode lead-out portion 10 of the capacitor element 7, byapplying a voltage to the conductive tape 16, while immersing in thepolymerization solution 18, with each anode lead-out portion 9 of theplurality of capacitor elements 7 containing the conductive substanceadhered to the conductive tape 16.

[0192] In this process, since the anode lead-out portion 9 of theplurality of capacitor elements 7 is adhered to the conductive tape 16,by applying a voltage between the conductive tape 16 and the negativeelectrode 19, the polymerization starting from the surface of theconductive tape 16 spreads to each cathode lead-out portion 10 of eachcapacitor element 7, so that a polymerization film is formed on thecathode lead-out portion 10 of each capacitor element 7. Thus, theproductivity is notably enhanced.

[0193] In this exemplary embodiment, as shown in FIG. 4, a plurality ofcapacitor elements 7 are integrally projected and formed in thedirection orthogonal to the longitudinal direction of the core material5, at both sides in the longitudinal direction of the band-shaped corematerial 5. Accordingly, at the time of forming polymerization film, theplurality of capacitor elements 7 can be handled as one body, and hencethe productivity is improved.

[0194] These capacitor elements 7 can be formed easily by forming slits6 in the direction orthogonal to the core material 5, at specifiedintervals as shown in FIG. 4, in the longitudinal direction of theband-shaped core material 5.

[0195] Further, as shown in FIG. 2, the projecting root of the capacitorelement 7 projecting in the direction orthogonal to the both sides inthe longitudinal direction of the band-shaped core material 5 is theanode lead-out portion 9, and the conductive tape 16 is adhered to thissurface of the anode lead-out portion 9. The projecting root side ofeach capacitor element 7 at both sides of the core material 5 is theanode lead-out portion 9, and its projecting root side is the centralpart of the core material 5, and one conductive tape 16 is adhered tothe central part of the core material 5. In this method, the distancebetween the cathode lead-out portion 10 of each capacitor element 7 andthe conductive tape 16 at both sides of the core material 5 is stable.As a result, a homogeneous polymerization film can be formed on thecathode lead-out portion 10 of each capacitor element 7.

[0196] As shown in FIG. 4 and FIG. 5, in the region of the core material5 corresponding to both sides in the longitudinal direction of theconductive tape 16, a long insulating tape 8 is adhered. The insulatingtape 8 has a higher flatness than the surface of the core material 5.The conductive tape 16 is adhered to the insulating tape 8. In thisconstitution, the following effects are obtained. That is, since thesurface of the insulating tape 8 has a higher flatness than the corematerial 5 forming the formation film, it is easier to adhere theconductive tape 16. Further, in a later process, it is easy to peel offthe conductive tape 16. As a result, the productivity is heightened.Moreover, by the insulating tape 8, the anode lead-out portion 9 andcathode lead-out portion of each capacitor element 7 are separated, andwhen forming the electrolytic polymerization film, invasion of thepolymerization film into the anode lead-out portion 9 side can beprevented.

[0197] As shown in FIG. 6 and FIG. 7, the polymerization tank 17 may becomposed also as shown in FIG. 6 and FIG. 7. That is, the polymerizationtank 17 has a long shape, and a plurality of long polymerization tanksare disposed. The productivity is further increased by immersing theband-shaped core material 5 to which the conductive tape 16 is adhered,in the polymerization solution 18 in each polymerization tank of theplurality of polymerization tanks.

[0198] By the long shape of each polymerization tank, the volume of thepolymerization solution 18 can be decreased.

[0199] Also as shown in FIG. 6 and FIG. 7, in an alternative method, theband-shaped core material 5 to which the conductive tape 16 is adheredis put in the polymerization solution 18 at one side of the longpolymerization tank 17, and the band-shaped core material 5 is moved soas to go out of the polymerization solution 18 at other side of thepolymerization tank 17. In this method, as the conductive high polymerfilm, the polymerization film can be continuously and sequentiallyformed on the cathode lead-out portion 10 of each capacitor element 7,from one side to other side in the polymerization tank 17. Further, thecore material on which the polymerization film is formed is drawn out ofthe polymerization tank 17, and can be moved to the next step.Accordingly, the productivity is further enhanced.

[0200] In other method, the polymerization solution 18 may be allowed toflow into the polymerization tank 17 from a first overflow 21 at oneside of the polymerization tank 17, and flow out of the polymerizationtank 17 from a second overflow 22 at other side of the polymerizationtank 17. Thus, as the polymerization solution 18 flows in and outsequentially in the polymerization tank 17, drop of concentration of thepolymerization solution 18 in the polymerization tank 17 is suppressed,and the polymerization film is formed stably.

[0201] In this case, preferably, the speed of the polymerizationsolution 18 moving from one side to other side of the polymerizationtank 17 should be nearly same as the speed of the core material 5. Inthis method, the relative position of each capacitor element 7 of thecore material 5 and the polymerization solution 18 contacting therewithis almost constant. The relative state of the both is stagnant, notmoving, so that the polymerization film may be formed stably. Hence, itis easier to form the polymerization film on the cathode lead-outportion 10 of each capacitor element 7.

[0202] At least in the lower part of the polymerization solution 18 atone side of the polymerization tank 17, an immersed first driven roller23 is disposed. At least in the lower part of the polymerizationsolution 18 at other side of the polymerization tank 17, an immersedfirst tension roller 24 is disposed. The band-shaped core material 5 towhich the conductive tape 16 is adhered is brought into contact with thelower part of the first driven roller 23 and first tension roller 24,and is moved from one side to other side of the polymerization tank 17.That is, by the first driven roller 23 at one side of the polymerizationtank 17, the band-shaped core material 5 is put into the polymerizationsolution 18, and by the first tension roller 24 at the other side, aproper tension is applied to the core material 5, and it is moved inthis state in the polymerization tank 17. As a result, an appropriatepolymerization film may be formed on each capacitor element 7.

[0203] As shown in FIG. 6, from above at one side of the polymerizationtank 17 toward the lower part of the first driven roller 23, the corematerial 5 to which the conductive tape 16 is adhered is moved in thepolymerization solution 18 in an inclined state of 30° or less. In thismethod, the conductive tape 16 smoothly moves into the polymerizationsolution 18 without peeling from the core material 5. As a result, thepolymerization film is formed stably on the plurality of capacitorelements 7 provided in the longitudinal direction of the band-shapedcore material 5.

[0204] Also from the first driven roller 23 of the polymerization tank17, the polymerization solution flows into the polymerization tank 17through the overflow 21 at one side. The bottom 17 a of thepolymerization tank 17 at one side has a slope inclined downward to thefirst driven roller 23 side. In this constitution, the polymerizationsolution 18 flowing into the polymerization tank 17 is a laminar flow,thereby preventing formation of waves on the polymerization solution 18in the polymerization tank 17. As a result, the polymerization film isformed stably on each capacitor element 7.

[0205] From the lower part of the first tension roller 24 at other sideof the polymerization tank 17 to above the polymerization tank 17, thecore material 5 to which the conductive tape 16 is adhered is moved outof the polymerization solution 18 at an inclination of 30° or less. Inthis constitution, the conductive tape 16 is prevented from being peeledfrom the core material 5. As a result, together with the conductive tape16, the core material 5 can be stably moved to the downstream side.

[0206] Also from the first tension roller 24 at other side of thepolymerization tank 17, the polymerization solution 18 is designed toflow out of the polymerization tank 17 from the overflow 22 at otherside. The bottom 17 b of the polymerization tank 17 at other end sidehas a slope inclined upward to the other end side of the polymerizationtank 17 from the first tension roller 24. Accordingly, thepolymerization solution flowing out of the polymerization tank 17 is alaminar flow, and hence formation of waves on the polymerizationsolution 18 in the polymerization tank 17 can be prevented. As a result,a polymerization film is formed stably on each capacitor element 7.

[0207] As shown in FIG. 7, each first driven roller 23 is disposed atone side of each polymerization tank 17 of the plurality ofpolymerization tanks 17 disposed in parallel. One through-shaft 25penetrates the center shaft of the plurality of driven rollers 23. Ithence simplifies the support structure of the plurality of first drivenrollers 23. Moreover, the position of the driven rollers 23 in eachpolymerization tank 17 is uniform. Accordingly, the immersion positionof the core material 5 into the polymerization solution 18 in eachpolymerization tank 17 is uniform. As a result, a polymerization film isformed stably in each capacitor element 7 of each core material 5.

[0208] As shown in FIG. 11, the plurality of first driven rollers 23have a plurality of ball bearings 26 installed between the through-shaft25 and first driven rollers 23. The ball bearings 26 are disposed abovethe liquid surface of the polymerization solution 18. In thisconstitution, the rotation of the first driven roller 23 is smooth. Italso prevents occurrence of rotation failure of ball bearings 26 due tosticking of polymerization solution 18. Accordingly, the first drivenroller 23 adheres the conductive tape 16, and operates together with theband-shaped core material 5. As a result, the core material 5 is movedwithout being interfered.

[0209] Also as shown in FIG. 11 and FIG. 12, the center line portion ofthe outer circumference 23 a of the first driven roller 23 has a curvedsurface projecting in the outer circumferential direction. In thisconstitution, the core material 5 is prevented from being deviated innposition from the center line portion of the first driven roller 23. Asa result, the core material 5 is stably guided into one side of thepolymerization tank 17 by the first driven roller 23.

[0210] As shown in FIG. 7 and FIG. 13, one drive shaft 27 penetrates thecenter shaft of the plurality of first tension rollers 24. Thus, bydriving the plurality of parallel first tension rollers 24 by one driveshaft 27, the drive mechanism is simplified. In each one of the parallelpolymerization tanks 17, the first tension roller 24 is almost uniform.In addition, the tension applied to the band-shaped core material 5 isnearly uniform. Accordingly, the moving state of the band-shaped corematerial 5 in each polymerization tank 17 is stable, so that apolymerization film is formed stably.

[0211] As shown in FIG. 13, the outer circumference 24 a of each firsttension roller 24 has a flat surface. In this constitution, the outercircumference 24 a and the band-shaped core material 5 to which theconductive tape 16 is adhered contact and slide on a flat surface. Inthis constitution, tension application by the first tension roller 24 isstabilized.

[0212] Although not shown in the drawings, the bottom of thepolymerization tank 17 in FIG. 7 has a constitution for passing watercontrolled in temperature to a specified temperature. The watercontrolled in temperature to a specified temperature has a largerthermal capacity than gas, and hence the temperature of thepolymerization solution 18 in the polymerization tank 17 is easilystabilized at the specified temperature. As a result, the polymerizationreaction is stable.

[0213] As shown in FIG. 7 and FIG. 8, a lid 28 is fitted to the openingat the upper side of each long polymerization tank 17. The lower part ofa spacer 29 provided at the lower side of this lid 28 is pushed into thepolymerization solution 18. In this constitution, the evaporation spaceabove the polymerization solution 18, and the exposed area of thesurface of the polymerization solution 18 are decreased. As a result,the evaporation amount of the polymerization solution 18 is decreased,and the economy is improved.

[0214] Besides, since the spacer is pushed into the polymerizationsolution, the liquid level may be higher if the volume of thepolymerization solution 18 is small. In this constitution, the distancebetween the negative electrode 19 and the band-shaped core material 5may be extended. As a result, bubbles formed in the negative electrode19 hardly stick to the portion of the band-shaped core material 5. As aresult, a polymerization film is formed stably on the cathode lead-outportion 10 of the capacitor element 7 of the band-shaped core material5.

[0215] Back to FIG. 8, the lower part of the spacer 29 in thepolymerization tank 17 has such a structure as to move the core material5 to which the conductive tape 16 is adhered from one side to other sideof the polymerization tank 17. By moving the core material 5 to whichthe conductive tape 16 is adhered in the lower part in thepolymerization tank 17 underneath the spacer 29, the oligomer generatedat the time of forming the polymerization film settles in the downwardportion of the core material 5. As a result, the forming efficiency ofpolymerization film is enhanced.

[0216] The lower part of the spacer 29 has a slope inclined upward. Inthis constitution, bubbles formed in the negative electrode 19 moveupward. In the capacitor element 7 of the band-shaped core material 5moving below, the forming efficiency of polymerization film is enhanced.

[0217] Together with the above constitution, the negative electrode 19is disposed above the lower end of the spacer 29. This negativeelectrode 19 is inclined upward. Accordingly, bubbles formed in thenegative electrode 19 move upward, and hardly stay at the lower end ofthe spacer 29. As a result, in the capacitor element 7 of theband-shaped core material 5 moving below, the forming efficiency ofpolymerization film is improved.

[0218] The spacer 29 is made of vinyl chloride. Hence, the spacer 29does not degenerate, and the polymerization solution 18 does notdegenerated due its degeneration. As a result, a polymerization film isformed stably on the capacitor element 7 of the band-shaped corematerial 5.

[0219] As shown in FIG. 8, the moving part 17 a of the core material 5in the lower part of the polymerization tank 17 has a smaller sectionalarea than the storage part 17 b of the upper spacer 29 and negativeelectrode 19. In this constitution, disturbance of polymerizationsolution 18 formed in the storage part 7 b has hardly any effect on thelower moving part 7 a. As a result, in the moving part 7 a of the corematerial 5, a polymerization film is formed stably on the capacitorelement 7.

[0220] Also in FIG. 8, the conductive tape 16 is adhered only to theupper side of the core material 5. At the upper side of the corematerial 5 at the upper side of the negative electrode 19, theconductive tape 16 is adhered. Accordingly, formation of polymerizationfilm from the upper side of the conductive tape 16 starts, andconsequently the polymerization film is formed so as to grow from theconductive tape 16 to the face side and back side of the cathodelead-out portion 10 of the capacitor element 7. Since the conductivetape 16 is not disposed at the lower side of the core material 5, theadhering step of conductive tape 16 to the lower side is not necessary.As a result, the productivity is enhanced.

[0221] As shown in FIG. 6, a weir 30 is installed in the liquid levelpart between the immersing part of the core material 5 into thepolymerization solution 18 at one side of the polymerization tank 17,and the first driven roller 23. By this weir 30, when the core material5 moves to the part to be immersed in the polymerization solution 18,bubbles formed in the negative electrode are prevented from sticking tothe core material 5. Bubbles formed in the negative electrode andfloating to the liquid surface are prevented from moving in thedirection of the core material 5. Sticking of bubbles to the corematerial 5 is avoided. Moreover, defective forming of polymerizationfilm due to bubbles is prevented.

[0222] As shown in FIG. 6, FIG. 15, and FIG. 16, at one side of thepolymerization tank 17, a first current feed roller 31 for composingfirst voltage applying means is disposed. By this current feed roller 31and a lower roller 32, the conductive tape 16 is adhered to the corematerial 5. Since the first voltage applying means is composed of thefirst current feed roller 31 for pressing the conductive tape 16 to thecore material 5, the constitution is simplified. Further, since thefirst current feed roller 31 presses the conductive tape 16 to the corematerial 5, this conductive tape 16 is kept in a pressed state. Hence,application of voltage to the conductive tape 16 is stable. As a result,a polymerization film is stably formed on the capacitor element 7.

[0223] A dust collecting squeegee 33 abuts against the outercircumference of the first current feed roller 31. In this constitution,dust and foreign matter are removed from the outer circumference of thefirst current feed roller 31. Hence, voltage can be applied stably fromthe first current feed roller 31 to the conductive tape 16. As a result,a polymerization film is formed stably on the capacitor element 7.

[0224] As shown in FIG. 16, a guide 34 for preventing lateral deviationof the conductive tape 16 is provided. On the other hand, second andthird driven rollers 34, 35 in FIG. 15 prevent lateral deviation of thecore material 5.

[0225] That is, at the upstream side of the first current feed roller 31for composing the first voltage applying means, there are second andthird driven rollers 34, 35 projecting in the outer circumferentialdirection in the center line portion of the outer circumference. Throughthese second and third driven rollers 34, 35, the core material 5 issupplied in the direction of the first current feed roller 31. Since thecenter line portion of the outer circumference of the second and thirddriven rollers 34, 35 is projecting in the outer circumferentialdirection, deviation of the band-shaped core material 5 is corrected bythe second and third driven rollers 34, 35. Therefore, the core material5 moves into the first current feed roller 31 without deviation. As aresult, adhering of core material 5 to the conductive tape 16, andapplication of voltage to the conductive tape 16 are done stably.

[0226] In FIG. 15, meanwhile, a spring 36 is provided for thrusting thefirst current feed roller 31 to the roller 32 side.

[0227] As shown in FIG. 6 and FIG. 14, at the upstream side of the firstcurrent feed roller 31, a reel 37 is installed in a laminated state ofthe conductive tape 16 and resin-made separator 36. Between this reel 37and first current feed roller 31, second tension rollers 38 a, 38 b areinstalled. At the downstream side of the second tension rollers 38 a, 38b, the separator 36 is peeled off from the conductive tape 16. That is,the conductive tape 16 and separate 36 are laminated with each other,and the laminated conductive tape 16 and separator 36 are wound aroundthe reel 37. Therefore, the conductive tape 16 being let off from thereel 37 is hardly set in curled state even after the separator 36 ispeeled off. Accordingly, the conductive tape 16 is stably supplied intothe first current feed roller 31 at the downstream side, and theconductive tape 16 is stably adhered to the band-shaped core material 5.

[0228] In FIG. 6, the laminated body of the conductive tape 16 andseparator 36 is held by the second tension rollers 38 a, 38 b. Thetension outside of one side of the polymerization tank 17 is applied tothe separator. In this case, since the conductive tape 16 and separator36 are formed in a laminated body, this laminated body has a highstrength, and a sufficient tension can be applied.

[0229] As shown in FIG. 14, a position defining plate 39 of conductivetape 16 is disposed at both sides of the second tension roller 38 a. Inthis constitution, in the part of the second tension roller 38 a,deviation of the laminated body of the conductive tape 16 and separator36 is prevented. Accordingly, a required tension is stably applied bythe second tension rollers 38 a, 38 b.

[0230] In FIG. 14, a spring 40 has a role of thrusting the secondtension roller 38 b to the 38 a side.

[0231] A suction duct 41 has a role of sucking and recovering the peeledseparator 36.

[0232] As shown in FIG. 17, at the upstream side of the second and thirddriven rollers 34, 35 in FIG. 6, a voltage application terminal 42contacts with the anode lead-out portion 9 of the core material 5. Thevoltage applied from this voltage application terminal 42 to the corematerial 5 is a voltage between the energization voltage to theconductive tape 16 by a first current feed roller 31 mentioned below andthe energization voltage to the negative electrode 19, and is same asthe voltage in the portion of the conductive tape immersed in thepolymerization solution or a higher voltage. The relation of thesevoltages is described in detail later.

[0233] The formation film on the surface of the core material 5 is analuminum oxide film. The voltage application terminal 42 is made ofstainless steel. The stainless steel has an excellent weatherresistance. When the voltage application terminal 42 is pressed to thelower roller 44 side by a spring 43, the aluminum oxide film on thesurface of the band-shaped core material 5 is broken by the voltageapplication terminal 42, so that the voltage may be applied stably.Further, when the terminal 42 is rubbed by the hard aluminum oxide film,the stainless steel surface is also scarred, and the surface of thestainless steel is exposed. As a result, the voltage is applied stablyfrom the terminal 42 to the core material 5.

[0234] As shown in FIG. 18, at the downstream side of the first tensionroller 24 in FIG. 6, a peeling roller 45 is disposed outside of thepolymerization solution 18 in the polymerization tank 17. By thispeeling roller 45, the conductive tape 16 is peeled from the corematerial 5 in the orthogonal direction. In this constitution, theconductive tape 16 is peeled from the core material 5 smoothly.Accordingly, in this portion, it is peeled off stably, favorably andsmoothly. As a result, the conductive tape 16 and core material 5 aresmoothly moved to the downstream side individually. At the same time,cutting of the core material 5 made of aluminum foil is prevented.

[0235] In the running path of the conductive tape 16 at the downstreamside of the peeling roller 45 in FIG. 6 and FIG. 18, a cracking roller46 of a smaller diameter than this peeling roller 45 is disposed. Bythis cracking roller 46, the running path of the conductive tape 16 isbent in the orthogonal direction.

[0236] In this constitution, the polymerization film on the conductivetape 16 is cracked, and by this cracking, the polymerization film can beeasily removed from the conductive tape by a first peeling pawl 47 and asecond peeling pawl 48 in a subsequent process.

[0237] At the lower side of the conductive tape 16 of the first peelingpawl 47 and second peeling pawl 48, the peeling roller 46 and a roller49 are disposed. In this constitution, the first peeling pawl 47 andsecond peeling pawl 48 can be firmly pressed to the upper side of theconductive tape 16. As a result, the effect of peeling thepolymerization film from the upper side of the conductive tape 16 isenhanced.

[0238] As shown in FIG. 19 and FIG. 20, at least one of the firstpeeling pawl 47 and second peeling pawl 48 has a leading end branchedinto a plurality. In this constitution, the removing effect of thepolymerization film at the leading end is enhanced.

[0239] After the conductive tape 16 is bent by the cracking roller 46,the first peeling pawl 47 contacts with the surface of the conductivetape 16. In this constitution, the cracked polymerization film is easilyremoved by the first peeling pawl 47. A large amount of polymerizationfilm removed by the first peeling pawl 47 is sucked and removed bysuction means 50 disposed on the surface of the first peeling pawl 47.As a result, re-sticking of the polymerization film at the upstream ordownstream is prevented, and occurrence of troubles is prevented.

[0240] The running path of the conductive tape 16 between the peelingroller 45 and cracking roller 46 has a space for drying thepolymerization film on the surface of the conductive tape 16. By dryingthe polymerization film sufficiently at this position, cracks may beeffectively formed in the polymerization film on the conductive tape 16by the cracking roller 46. Accordingly, it is much easier to remove bythe first peeling pawl 47 and second peeling pawl 48 in the subsequentprocess.

[0241] As shown in FIG. 21, at the downstream side of the second peelingpawl 48 in FIG. 6, a second current feed roller 51 for composing secondvoltage applying means is disposed, and also a roller 52 is disposedunderneath the conductive tape 16 in this portion. In this constitution,at one side of the polymerization tank 17 of the conductive tape 16, avoltage is applied from the first current feed roller 31, and at otherside by applying a voltage from the second current feed roller 51, theforming efficiency of polymerization film is enhanced.

[0242] In the running path of the conductive tape 16 at the downstreamside of the second current feed roller 51 in FIG. 6, tension rollers 53a, 53 b are disposed for pulling the conductive tape 16. By puling theconductive tape by the tension rollers 53 a, 53 b, the band-shaped corematerial 5 can be moved from one side to other side of thepolymerization tank 17. By applying this tensile force only to theconductive tape 16 by the tension rollers 53 a, 53 b, breakage of theband-shaped core material 5 can be prevented.

[0243] At the downstream side of the second current feed roller 51, bydisposing the tension rollers 53 a, 53 b, when the conductive tape 16passes the second current feed roller 51, tension is also applied to theconductive tape 16. Hence, it prevents formation of gap between thesecond current feed roller 51 and conductive tape 16. As a result, thevoltage is supplied stably from the second current feed roller 51 to theconductive tape 16.

[0244] As shown in FIG. 6, a take-up reel 54 of conductive tape 16 isdisposed at the downstream side of the tension rollers 53 a, 53 b. Inthis constitution, in the process after the tension rollers 53 a, 53 b,the conductive tape 16 can be taken up smoothly. As a result,malfunction due to entangling of the conductive tape 16 or the like isprevented.

[0245] As mentioned above, the first current feed roller 31 is disposedat one side of the polymerization tank 17 as first voltage applyingmeans for applying voltage to the conductive tape 16, and the secondcurrent feed roller 51 is disposed at other side of the polymerizationtank 17 as second voltage applying means for applying voltage to theconductive tape 16. In such constitution, as indicated by line A in FIG.9, the central part in the longitudinal direction of the conductive tape16 has the lowest potential. As a result, large potential fluctuationcan be suppressed.

[0246] On the other hand, a plurality of negative electrodes 19 aredisposed at specified intervals in the longitudinal direction in thepolymerization tank 17. The both inner and outer negative electrodes ofthe plurality of negative electrodes 19 are as shown in FIG. 9, in whichthe voltage of the conductive tape 16 applied from the first currentfeed roller 31 and second current feed roller 51 is high as indicated byline A, and therefore it is heightened as indicated by line B. Since thevoltage is low in the central part of the conductive tape 16, thevoltage of the negative electrode 19 is gradually lower toward thecentral part side. Therefore, the potential difference (A-B) of thepotential of the conductive tape 16 at each part in the longitudinaldirection and the potential of the corresponding negative electrode 19is nearly constant. Thus, the polymerization film is formed stably.

[0247] The voltage applied from the voltage applying terminal 42 to thecore material 5 is indicated by C in FIG. 9. This voltage is constantbecause no current flows.

[0248] The foil load voltage applied to the core material 5 is (C-B). Bylowering the voltage C, increase of foil load voltage is prevented.Therefore, it prevents breakdown of the formation film formed on theface and back sides of the core material 5.

[0249] The withstand voltage of the formation film is (C-D). The voltagemust be applied so that (B-C) may settle between (C-D). By spacing theplurality of negative electrodes 19 at specified intervals, bubblesformed in each negative electrode 19 are prevented from staying still inthe adjacent negative electrodes 19, and the polymerization reaction inthis area proceeds without trouble. As a result, the polymerization filmof each capacitor element 7 is formed stably.

[0250] The negative electrode 19 is made of stainless steel or nickel.In this constitution, deterioration of the negative electrode 19 isprevented. As a result, a polymerization film is formed in the capacitorelements 7 of the parts of the band-shaped material 5 stably for a longperiod.

[0251] The conductive tape 16 is made of stainless steel or nickel. Inthis constitution, when performing polymerization reaction by applying avoltage to the conductive tape 16, the conductive tape 16 is preventedfrom eluting into the polymerization solution 18. Hence, polymerizationreaction is conducted stably by using the conductive tape 16.

[0252]FIG. 10 shows energization in each polymerization tank 17 of theplurality of polymerization tanks 17 as shown in FIG. 7. Switches 55 to57 are provided independently for individual polymerization tanks 17. Bythe individual constitution, polymerization reaction is performedindependently in each tank.

[0253] The polymerization solution 18 supplied into the polymerizationtank 17 from the overflow 21 at one side of the polymerization tank inFIG. 6 has a mixed polymerization solution mixing the polymerizationsolution 18 flowing out of the polymerization tank 17 from the overflow21 at other side of the polymerization tank 17. In the polymerizationsolution 18 flowing out of the tank from other side of thepolymerization tank 17, since oligomer is formed by polymerizationreaction, by mixing it into the polymerization solution 18 flowing intothe tank from one side of the polymerization tank 17, a polymerizationfilm is formed efficiently in the capacitor element in thepolymerization tank 17.

[0254] Thus, since the anode lead-out portion of the plurality ofcapacitor elements is adhered to the conductive tape, by applying avoltage to the conductive tape, the polymerization starting from thesurface of the conductive tape spreads to the cathode lead-out portionof each capacitor element adhered to this conductive tape, and apolymerization film is formed on the cathode lead-out portion of eachcapacitor element. As a result, an excellent capacitor characteristic isobtained, and the productivity is enhanced remarkably.

What is claimed is:
 1. A manufacturing method of solid electrolyticcapacitor comprising the steps of: (a) supplying a capacitor elementmanufacturing apparatus, said capacitor element manufacturing apparatusincluding a polymerization tank, a polymerization solution contained insaid polymerization tank, and a negative electrode put in saidpolymerization solution in the polymerization tank, (b) supplying a corematerial having a plurality of capacitor elements, each capacitorelement of said plurality of capacitor elements having an anode lead-outportion and a cathode lead-out portion, (c) forming a formation film onthe surface of said core material, (d) installing a conductive substanceon said formation film, (e) adhering each anode lead-out portion of theplurality of capacitor elements having the conductive substance to aconductive tape, (f) immersing said core material having the anodelead-out portion adhered to the adhesive tape in the polymerizationsolution, and (g) forming a polymerization film on the cathode lead-outportion of the capacitor element by applying a voltage to the conductivetape.
 2. The manufacturing method of solid electrolytic capacitor ofclaim 1 , wherein said core material has a band shape.
 3. Themanufacturing method of solid electrolytic capacitor of claim 2 ,wherein said polymerization tank has a long shape.
 4. The manufacturingmethod of solid electrolytic capacitor of claim 2 , wherein said step ofsupplying the core material includes a step of forming integrally theplurality of capacitor elements projected in a direction orthogonal tothe longitudinal direction, in the longitudinal direction of said corematerial, and each anode lead-out portion is positioned at the projectedroot side of the plurality of the projected capacitor elements.
 5. Themanufacturing method of solid electrolytic capacitor of claim 2 ,wherein said step of supplying the core material includes a step offorming integrally the plurality of capacitor elements projected in adirection orthogonal to the longitudinal direction of the core material,at both sides of the longitudinal direction of the band-shaped corematerial.
 6. The manufacturing method of solid electrolytic capacitor ofclaim 2 , wherein said step of supplying the core material includes astep of forming a plurality of slits in the direction orthogonal to thelongitudinal direction, at every specific interval in the longitudinaldirection of the core material, and each capacitor element of theplurality of capacitors is formed between slits of the plurality ofslits.
 7. The manufacturing method of solid electrolytic capacitor ofclaim 2 , wherein said step of supplying the core material includes astep of forming integrally the plurality of capacitor elements projectedin the direction orthogonal to the longitudinal direction, in thelongitudinal direction of the band-shaped core material, said anodelead-out portion is positioned at the root side of the plurality ofprojected capacitor elements, and said conductive tape is adhered to thesurface of the anode lead-out portion.
 8. The manufacturing method ofsolid electrolytic capacitor of claim 2 , further comprising a step ofadhering a long insulating tape in the central region in thelongitudinal direction of the band-shaped core material, wherein saidinsulating tape has a smoother surface than said core material, and theconductive tape is adhered to the insulating tape.
 9. The manufacturingmethod of solid electrolytic capacitor of claim 3 , wherein saidlong-shaped polymerization tank has a plurality of long-shapedpolymerization tanks installed in parallel, and said step of immersingthe core material in the polymerization solution includes a step ofimmersing the band-shaped core material having the anode lead-outportion adhered to the conductive tape in each polymerization solutionin each long-shaped polymerization tank of the plurality of long-shapedpolymerization tanks.
 10. The manufacturing method of solid electrolyticcapacitor of claim 3 , wherein said band-shaped core material to whichthe conductive tape is adhered moves so as to get into thepolymerization solution from one end side of the long-shapedpolymerization tank, and go out of the polymerization solution fromother end side.
 11. The manufacturing method of solid electrolyticcapacitor of claim 3 , wherein said polymerization solution flows intothe polymerization tank from one end side of the long-shapedpolymerization tank, and flows out of the polymerization tank from theother end side of the polymerization tank.
 12. The manufacturing methodof solid electrolytic capacitor of claim 3 , wherein said core materialto which the conductive tape is adhered gets into the polymerizationsolution from one end side of the long-shaped polymerization tank, andmoves to go out of the polymerization solution from other end side, andthe polymerization solution flows into the polymerization tank from oneend side of the long-shaped polymerization tank, and flows out of thepolymerization tank from the other end side of the polymerization tank,and the flow speed of the polymerization solution and the moving speedof the core material are nearly the same.
 13. The manufacturing methodof solid electrolytic capacitor of claim 3 , wherein said capacitorelement manufacturing apparatus includes a first driven roller installedat one side in the polymerization tank, and a first tension rollerinstalled at other side in the polymerization tank, and at least thelower part of the first driven roller is immersed in the polymerizationsolution, at least the lower part of the first tension roller isimmersed in the polymerization solution, and the band-shaped corematerial to which the conductive tape is adhered abuts against the lowerpart of the first driven roller and the lower part of the first tensionroller, and is moved from one side to other side of the polymerizationtank.
 14. The manufacturing method of solid electrolytic capacitor ofclaim 13 , wherein from above at one side of the polymerization tanktoward the lower part of the first driven roller, the core material towhich the conductive tape is adhered is moved in the polymerizationsolution in an inclined state of 30° or less.
 15. The manufacturingmethod of solid electrolytic capacitor of claim 14 , wherein saidpolymerization solution flows into the polymerization tank from theupper direction than the first driven roller at one side of thepolymerization tank, and the polymerization tank at one side has aninclined bottom downward to the direction of installation of the firstdriven roller.
 16. The manufacturing method of solid electrolyticcapacitor of claim 13 , wherein from the lower part of the first tensionroller at other side of the polymerization tank toward the upper side ofthe polymerization tank, the core material to which the conductive tapeis adhered is moved out of the polymerization solution in an inclinedstate of 30° or less.
 17. The manufacturing method of solid electrolyticcapacitor of claim 13 , wherein said polymerization solution flows outof the polymerization tank from other end side of the polymerizationtank, and the polymerization tank at other end side has an inclinedbottom upward to the other end side from the tension roller.
 18. Themanufacturing method of solid electrolytic capacitor of claim 9 ,wherein said capacitor element manufacturing apparatus includes eachfirst driven roller installed at one side of each polymerization tank ofthe plurality of polymerization tanks, and one through-shaft penetratesthe central shaft of each first driven roller.
 19. The manufacturingmethod of solid electrolytic capacitor of claim 18 , wherein saidcapacitor element manufacturing apparatus includes a through-shaftformed in each first driven roller, and a ball bearing installed betweenthe first driven roller and through-shaft, and this ball bearing isplaced above the liquid level of the polymerization solution.
 20. Themanufacturing method of solid electrolytic capacitor of claim 13 ,wherein said first driven roller has an outer circumference curved sothat the center line portion may project in the outer circumferentialdirection, and the core material is moved while contacting with thecenter line portion.
 21. The manufacturing method of solid electrolyticcapacitor of claim 9 , wherein said capacitor element manufacturingapparatus includes each first tension roller installed at other side ofeach polymerization tank of the plurality of polymerization tanks, andone through-shaft penetrates the center shaft of each first tensionroller, and each tension roller is driven by driving of thethrough-shaft.
 22. The manufacturing method of solid electrolyticcapacitor of claim 13 , wherein said first tension roller has a flatouter circumference, and the core material moves while contacting withthe flat outer circumference of the first tension roller.
 23. Themanufacturing method of solid electrolytic capacitor of claim 1 ,wherein said polymerization tank has temperature control means, and thetemperature control means controls the temperature of the polymerizationsolution.
 24. The manufacturing method of solid electrolytic capacitorof claim 1 , wherein said polymerization tank is controlled at aspecified temperature by the water controlled at the specifiedtemperature.
 25. The manufacturing method of solid electrolyticcapacitor of claim 1 , wherein said polymerization tank has a spacerprojecting into the polymerization solution so as to separate from theupper surface of the polymerization solution.
 26. The manufacturingmethod of solid electrolytic capacitor of claim 1 , wherein saidpolymerization tank has a lid installed in the opening of the uppersurface, and a spacer installed at the lower side of the lid, and atleast a part of said spacer is projecting into the polymerizationsolution.
 27. The manufacturing method of solid electrolytic capacitorof claim 1 , wherein said step of immersing the core material to whichthe conductive tape is adhered in the polymerization solution includes astep of moving the core material to which the conductive tape is adheredfrom one side to other side of the polymerization tank through the lowerside of the spacer.
 28. The manufacturing method of solid electrolyticcapacitor of claim 27 , wherein said spacer has a lower part of a slopeinclined upward.
 29. The manufacturing method of solid electrolyticcapacitor of claim 27 , wherein said negative electrode is disposedabove the lower end of the spacer, and said step of applying voltage tothe conductive tape includes a step of applying a voltage between theconductive tape and negative electrode.
 30. The manufacturing method ofsolid electrolytic capacitor of claim 25 , wherein said spacer is madeof vinyl chloride.
 31. The manufacturing method of solid electrolyticcapacitor of claim 29 , wherein said negative electrode has a lower partin a shape inclined upward.
 32. The manufacturing method of solidelectrolytic capacitor of claim 27 , wherein said polymerization tankhas an upper space and a lower space, the lower space has a smallersectional area than the upper space, the spacer and the negativeelectrode are disposed on the upper space, and the core material passesthrough the lower space.
 33. The manufacturing method of solidelectrolytic capacitor of claim 1 , wherein said conductive tape isadhered only to the upper side of the core material.
 34. Themanufacturing method of solid electrolytic capacitor of claim 13 ,wherein said polymerization tank has an immersion region for immersingthe core material in the polymerization solution, and a weir installedon the liquid level between the immersing region and the first drivenroller.
 35. The manufacturing method of solid electrolytic capacitor ofclaim 2 , wherein said negative electrode has a plurality of negativeelectrodes disposed in the longitudinal direction.
 36. The manufacturingmethod of solid electrolytic capacitor of claim 35 , wherein eachnegative electrode of the plurality of negative electrodes is disposedat a specified interval, and the voltage applied to each negativeelectrode is individually different.
 37. The manufacturing method ofsolid electrolytic capacitor of claim 1 , wherein said negativeelectrode is made of at least one of stainless steel and nickel.
 38. Themanufacturing method of solid electrolytic capacitor of claim 35 ,wherein said capacitor element manufacturing apparatus includes firstvoltage applying means installed at one side of the polymerization tankand second voltage applying means installed at other side, and each oneof the first voltage applying means and second voltage applying meansapplies a voltage to the conductive tape.
 39. The manufacturing methodof solid electrolytic capacitor of claim 1 , wherein said capacitorelement manufacturing apparatus includes a first current feed rollerinstalled at one side of the polymerization tank, and the first currentfeed roller has an action of adhering the conductive tape to the corematerial, an action of pressing the conductive tape to the corematerial, and an action of applying a voltage to the conductive tape.40. The manufacturing method of solid electrolytic capacitor of claim 39, wherein said capacitor element manufacturing apparatus includes a dustcollecting squeegee abutting against the outer circumference of thefirst current feed roller, and the deposits adhering to the outercircumference of the first current feed roller are removed by said dustcollecting squeegee.
 41. The manufacturing method of solid electrolyticcapacitor of claim 39 , wherein said capacitor element manufacturingapparatus includes a second driven roller installed at the upstream sideof the first current feed roller, and the second driven roller has anouter circumference projecting in the outer circumferential direction inthe center line portion, and the core material is supplied in thedirection of the first current feed roller through said second drivenroller.
 42. The manufacturing method of solid electrolytic capacitor ofclaim 38 , wherein said capacitor element manufacturing apparatus has areel installed at the upstream side of the first current feed roller,the reel coils the conductive tape in a laminated state through aseparator, and the separator is peeled from the conductive tape betweenthe reel and the first current feed roller.
 43. The manufacturing methodof solid electrolytic capacitor of claim 42 , wherein said capacitorelement manufacturing apparatus has a second tension roller installedbetween the reel and the first current feed roller, and the secondtension roller grips a laminated body of the conductive tape andseparator, and the separator is peeled from the conductive tape at thedownstream side of said second tension roller.
 44. The manufacturingmethod of solid electrolytic capacitor of claim 43 , wherein saidcapacitor element manufacturing apparatus includes a position definingplate disposed at both sides of the second tension roller, and theposition defining plate defines the position of the conductive tape. 45.The manufacturing method of solid electrolytic capacitor of claim 1 ,wherein said conductive tape is made of at least one of stainless steeland nickel.
 46. The manufacturing method of solid electrolytic capacitorof claim 39 , wherein said step of applying a voltage includes a step ofapplying a voltage from the voltage application terminal to the corematerial by setting the voltage application terminal in contact with theanode lead-out portion of the core material at the upstream side of thefirst current feed roller, and the applied voltage is a voltage betweenthe energization voltage by the first current feed roller and theenergization voltage by the negative electrode, and is same or higherthan the voltage in the portion of the conductive tape immersed in thepolymerization solution.
 47. The manufacturing method of solidelectrolytic capacitor of claim 46 , wherein said formation film of thecore material has an aluminum oxide film, and the voltage applicationterminal is made of stainless steel.
 48. The manufacturing method ofsolid electrolytic capacitor of claim 13 , wherein said capacitorelement manufacturing apparatus includes a peeling roller installedoutside of the polymerization solution in the polymerization tank at thedownstream side of the first tension roller, and said peeling rollerpeels off the conductive tape in the orthogonal direction from the corematerial.
 49. The manufacturing method of solid electrolytic capacitorof claim 48 , wherein said capacitor element manufacturing apparatusincludes a cracking roller installed in the running path of theconductive tape at the downstream side of the peeling roller, and thiscracking roller has a smaller diameter than the peeling roller, and thecracking roller bends the running path of the conductive tape in theorthogonal direction.
 50. The manufacturing method of solid electrolyticcapacitor of claim 49 , wherein said running path of the conductive tapebetween the peeling roller and the cracking roller has a dry space ofthe polymerization film formed on the surface of the conductive tape.51. The manufacturing method of solid electrolytic capacitor of claim 49, wherein said capacitor element manufacturing apparatus includes afirst peeling pawl installed at the downstream side of the crackingroller, and the first peeling pawl contacts with the surface of theconductive tape bent by the cracking roller.
 52. The manufacturingmethod of solid electrolytic capacitor of claim 51 , wherein saidcapacitor element manufacturing apparatus includes a second peeling pawlinstalled at the downstream side of the first peeling pawl, and saidsecond peeling pawl contacts with the upper surface of the conductivetape.
 53. The manufacturing method of solid electrolytic capacitor ofclaim 51 , wherein said first peeling pawl has a leading end branchedinto a plurality.
 54. The manufacturing method of solid electrolyticcapacitor of claim 51 , wherein said capacitor element manufacturingapparatus includes a roller disposed at the lower side of the conductivetape of the first peeling pawl.
 55. The manufacturing method of solidelectrolytic capacitor of claim 51 , wherein said capacitor elementmanufacturing apparatus includes suction means installed on the firstpeeling pawl.
 56. The manufacturing method of solid electrolyticcapacitor of claim 51 , wherein said capacitor element manufacturingapparatus includes a second current feed roller installed at thedownstream side of the first peeling pawl.
 57. The manufacturing methodof solid electrolytic capacitor of claim 51 , wherein said capacitorelement manufacturing apparatus includes a second current feed roller assecond voltage applying means installed at the downstream side of thesecond peeling pawl.
 58. The manufacturing method of solid electrolyticcapacitor of claim 48 , wherein said capacitor element manufacturingapparatus includes a tension roller installed on the running path of theconductive tape at the downstream side of the peeling roller, and saidtension roller pulls the conductive tape.
 59. The manufacturing methodof solid electrolytic capacitor of claim 48 , wherein said capacitorelement manufacturing apparatus includes a tension roller installed atthe downstream side of the second current feed roller.
 60. Themanufacturing method of solid electrolytic capacitor of claim 59 ,wherein said capacitor element manufacturing apparatus includes atake-up reel installed at the downstream side of the tension roller, andsaid take-up reel takes up the conductive tape.
 61. The manufacturingmethod of solid electrolytic capacitor of claim 1 , wherein saidconductive substance has a manganese dioxide layer.
 62. Themanufacturing method of solid electrolytic capacitor of claim 1 ,wherein said step of forming the conductive substance includes a step ofapplying an aqueous solution of manganese nitrate on the formation film,and a step of forming a manganese dioxide layer by pyrolysis of theapplied aqueous solution of manganese nitrate.
 63. The manufacturingmethod of solid electrolytic capacitor of claim 1 , wherein saidpolymerization solution contains at least one monomer selected from thegroup consisting of pyrrole, thiophene, furan and their derivatives, andsaid step of forming the polymerization film includes a step of forpolymerizing at least one monomer electrolytically.
 64. Themanufacturing method of solid electrolytic capacitor of claim 1 ,wherein said polymerization solution is a mixed polymerization solutionof a first polymerization solution and a second polymerization solutionflowing out from other side of the polymerization tank.
 65. Themanufacturing method of solid electrolytic capacitor of claim 1 ,wherein said capacitor element manufacturing apparatus includes apeeling roller disposed at other end of the polymerization tank, andother device disposed at the downstream side of said peeling roller,said peeling roller peels off the conductive tape from the corematerial, and said other device includes at least one selected from thegroup consisting of cracking roller, peeling pawl, roller, suctionmeans, second current feed roller, tension roller, and take-up reel. 66.A manufacturing apparatus of solid electrolytic capacitor comprising: asupplying device for supplying a core material having a plurality ofcapacitor elements, each capacitor element of said plurality ofcapacitor elements having an anode lead-out portion and a cathodelead-out portion, a formation film forming device for forming aformation film on the surface of said core material, a conductivesubstance forming device for installing a conductive substance on saidformation film, an adhering device for adhering the plurality ofcapacitor elements having the conductive substance to a conductive tape,a polymerization device for forming a conductive polymerization film onthe surface of the cathode lead-out portion of the core material adheredto the conductive tape, said polymerization device including apolymerization solution and a peeling device for peeling the conductivetape from the core material forming the polymerization film.
 67. Themanufacturing apparatus of solid electrolytic capacitor of claim 66 ,wherein said core material has a band shape.
 68. The manufacturingapparatus of solid electrolytic capacitor of claim 67 , wherein saidpolymerization device has a long shape.
 69. The manufacturing apparatusof solid electrolytic capacitor of claim 67 , wherein said core materialhas a plurality of capacitor elements projected and formed integrally inthe direction orthogonal to the longitudinal direction, in thelongitudinal direction of the band-shaped core material, said anodelead-out portion is positioned at the root side of the plurality ofprojected capacitor elements.
 70. The manufacturing apparatus of solidelectrolytic capacitor of claim 66 , further comprising an insulatingtape adhering device for adhering a long insulating tape in the centralregion in the longitudinal direction of the band-shaped core material,wherein said insulating tape has a smoother surface than said corematerial, and the conductive tape is adhered to the insulating tape. 71.The manufacturing apparatus of solid electrolytic capacitor of claim 68, wherein said long-shaped polymerization device has a plurality oflong-shaped polymerization tanks installed in parallel, and saidband-shaped core material having the anode lead-out portion adhered tothe conductive tape is immersed in each polymerization solution in eachlong-shaped polymerization tank of the plurality of long-shapedpolymerization tanks.
 72. The manufacturing apparatus of solidelectrolytic capacitor of claim 68 , wherein said polymerizationsolution flows into the polymerization device from one end side of thelong-shaped polymerization tank, and flows out of the polymerizationdevice from the other end side of the polymerization tank.
 73. Themanufacturing apparatus of solid electrolytic capacitor of claim 68 ,wherein said core material to which the conductive tape is adhered getsinto the polymerization solution from one end side of the long-shapedpolymerization device, and moves to go out of the polymerizationsolution from other end side, and the polymerization solution flows intothe polymerization device from one end side of the long-shapedpolymerization device, and flows out of the polymerization tank from theother end side of the polymerization device, and the flow speed of thepolymerization solution and the moving speed of the core material arenearly the same.
 74. The manufacturing apparatus of solid electrolyticcapacitor of claim 68 , further comprising a first driven rollerinstalled at one side in the polymerization device, and a first tensionroller installed at other side in the polymerization device, wherein atleast the lower part of the first driven roller is immersed in thepolymerization solution, at least the lower part of the first tensionroller is immersed in the polymerization solution, and the band-shapedcore material to which the conductive tape is adhered abuts against thelower part of the first driven roller and the lower part of the firsttension roller, and is moved from one side to other side of thepolymerization device.
 75. The manufacturing apparatus of solidelectrolytic capacitor of claim 74 , wherein from above at one side ofthe polymerization device toward the lower part of the first drivenroller, the core material to which the conductive tape is adhered ismoved in the polymerization solution in an inclined state of 30° orless.
 76. The manufacturing apparatus of solid electrolytic capacitor ofclaim 74 , wherein said polymerization solution flows into thepolymerization device from the upper direction than the first drivenroller at one side of the polymerization device, and the polymerizationdevice at one side has an inclined bottom downward to the direction ofinstallation of the first driven roller.
 77. The manufacturing apparatusof solid electrolytic capacitor of claim 71 , further comprising eachfirst driven roller installed at one side of each polymerization tank ofthe plurality of polymerization tanks, wherein one through-shaftpenetrates the central shaft of each first driven roller.
 78. Themanufacturing apparatus of solid electrolytic capacitor of claim 68 ,further comprising a through-shaft formed in each first driven roller,and a ball bearing installed between the first driven roller andthrough-shaft, wherein said ball bearing is placed above the liquidlevel of the polymerization solution.
 79. The manufacturing apparatus ofsolid electrolytic capacitor of claim 74 , wherein said first tensionroller has a flat outer circumference, and the core material moves whilecontacting with the flat outer circumference of the first tensionroller.
 80. The manufacturing apparatus of solid electrolytic capacitorof claim 68 , wherein said polymerization device has a spacer projectinginto the polymerization solution so as to separate from the upper surface of the polymerization solution.
 81. The manufacturing apparatus ofsolid electrolytic capacitor of claim 68 , wherein said polymerizationdevice has a lid installed in the opening of the upper surf ace, and aspacer installed at the lower side of the lid, and at least a part ofsaid spacer is projecting into the polymerization solution.
 82. Themanufacturing apparatus of solid electrolytic capacitor of claim 68 ,wherein said polymerization device has an upper space and a lower space,the lower space has a smaller sectional area than the upper space, thespacer and the negative electrode are disposed on the upper space, andthe core material passes through the lower space.
 83. The manufacturingapparatus of solid electrolytic capacitor of claim 74 , wherein saidpolymerization device has an immersion region for immersing the corematerial in the polymerization solution, and a weir installed on theliquid level between the immersing region and the first driven roller.84. The manufacturing apparatus of solid electrolytic capacitor of claim68 , wherein said polymerization device has a plurality of negativeelectrodes disposed in the longitudinal direction.
 85. The manufacturingapparatus of solid electrolytic capacitor of claim 84 , wherein eachnegative electrode of the plurality of negative electrodes is disposedat a specified interval, and the voltage applied to each negativeelectrode is individually different.
 86. The manufacturing apparatus ofsolid electrolytic capacitor of claim 84 , wherein said plurality ofnegative electrodes are made of at least one of stainless steel andnickel.
 87. The manufacturing apparatus of solid electrolytic capacitorof claim 66 , wherein said polymerization device includes first voltageapplying means installed at one side of the polymerization device andsecond voltage applying means installed at other side, and each one ofthe first voltage applying means and second voltage applying meansapplies a voltage to the conductive tape.
 88. The manufacturingapparatus of solid electrolytic capacitor of claim 66 , wherein saidpolymerization device includes a first current feed roller installed atone side of the polymerization device, and the first current feed rollerhas an action of adhering the conductive tape to the core material, anaction of pressing the conductive tape to the core material, and anaction of applying a voltage to the conductive tape.
 89. Themanufacturing apparatus of solid electrolytic capacitor of claim 88 ,wherein said polymerization device includes a dust collecting squeegeeabutting against the outer circumference of the first current feedroller, and the deposits adhering to the outer circumference of thefirst current feed roller are removed by said dust collecting squeegee.90. The manufacturing apparatus of solid electrolytic capacitor of claim88 , wherein capacitor element manufacturing apparatus includes a seconddriven roller installed at the upstream side of the first current feedroller, and the second driven roller has an outer circumferenceprojecting in the outer circumferential direction in the center lineportion, and the core material is supplied in the direction of the firstcurrent feed roller through said second driven roller.
 91. Themanufacturing apparatus of solid electrolytic capacitor of claim 88 ,further comprising a reel installed at the upstream side of the firstcurrent feed roller, wherein said reel coils the conductive tape in alaminated state through a separator, and the separator is peeled fromthe conductive tape between the reel and the first current feed roller.92. The manufacturing apparatus of solid electrolytic capacitor of claim91 , further comprising a second tension roller installed between thereel and the first current feed roller, wherein said second tensionroller grips a laminated body of the conductive tape and separator,wherein the separator is peeled from the conductive tape at thedownstream side of said second tension roller.
 93. The manufacturingapparatus of solid electrolytic capacitor of claim 92 , furthercomprising a position defining plate disposed at both sides of thesecond tension roller, wherein said position defining plate defines theposition of the conductive tape.
 94. The manufacturing apparatus ofsolid electrolytic capacitor of claim 74 , further comprising a peelingroller installed outside of the polymerization solution in thepolymerization tank at the downstream side of the first tension roller,wherein said peeling roller peels off the conductive tape in theorthogonal direction from the core material.
 95. The manufacturingapparatus of solid electrolytic capacitor of claim 94 , furthercomprising a cracking roller installed in the running path of theconductive tape at the downstream side of the peeling roller, whereinsaid cracking roller has a smaller diameter than the peeling roller, andthe cracking roller bends the running path of the conductive tape in theorthogonal direction.
 96. The manufacturing apparatus of solidelectrolytic capacitor of claim 95 , further comprising a first peelingpawl installed at the downstream side of the cracking roller, whereinsaid first peeling pawl contacts with the surface of the conductive tapebent by the cracking roller.
 97. The manufacturing apparatus of solidelectrolytic capacitor of claim 96 , further comprising a second currentfeed roller as the second voltage applying means installed at thedownstream side of the second peeling pawl.
 98. The manufacturingapparatus of solid electrolytic capacitor of claim 94 , furthercomprising a tension roller installed on the running path of theconductive tape at the downstream side of the peeling roller, whereinsaid tension roller pulls the conductive tape.
 99. The manufacturingapparatus of solid electrolytic capacitor of claim 98 , furthercomprising a take-up reel installed at the downstream side of thetension roller, wherein said take-up reel takes up the conductive tape.100. The manufacturing apparatus of solid electrolytic capacitor ofclaim 66 , further comprising a peeling roller disposed at other end ofthe polymerization tank, and other device disposed at the downstreamside of said peeling roller, wherein said peeling roller peels off theconductive tape from the core material, and said other device includesat least one selected from the group consisting of cracking roller,peeling pawl, roller, suction means, second current feed roller, tensionroller, and take-up reel.